Machine Safety Symposium Software Tools

Transcription

1 1 Machine Safety Symposium Software Tools Copyright 2016 Rockwell Automation, Inc. All rights reserved.

2 EN954 ISO Implications of Changing Standards Move towards global safety standards EN-954 (Safety Categories) officially withdrawn on January 1, 2012 EN ISO (Performance Levels) in effect since then ISO Specifies circuit performance in terms of performance levels (PL) Structure. Category Reliability. MTTFd Monitoring DC avg Risk Assessment criteria are defined and mapped to Required performance Levels (PLr) Based on severity, frequency & avoidance Risk Assessments evaluate the potential hazards in order to determine the required performance level. Copyright 2016 Rockwell Automation, Inc. All rights reserved.

3 Two Sides of Functional Safety Risk Assessment Model & Confirm PLr Determines (PLr) Confirms PLr Achieved Sistema Supports Both Sides of Analysis & Provides Critical Documentation

4 Risk Assessment A Foundation of Good Engineering Practice 4 Machine Characteristics/Limits Risk Analysis Hazard Identification Risk Estimation Risk Evaluation Too High OK Risk Reduction Risk Tolerable Next Hazard -Repeatable -Team Based -Task Hazard Oriented -Analyzes Severity, Frequency, Avoidance -Determines Appropriate PLr Risk Evaluation/Reduction -Mitigation Hierarchy -Solution Based On Structure, Reliability, & Monitoring -Confirms PLr is Achieved

5 Risk Estimation 5

6 ISO Risk Estimation Severity 6

7 ISO Risk Estimation Frequency 7

8 8 ISO Risk Estimation Avoidance PLr

9 Hierarchy of Risk Reduction Measures 9

10 Achieving PLr System Structure. Category Component Reliability.MTTFd Monitoring Capability. Diagnostic Coverage Common Cause Failure Analysis CCF 10

11 11 Achieving PLr With ISO13849 Flexibility System Structure. Category Component Reliability.MTTFd Monitoring Capability. Diagnostic Coverage Common Cause Failure Analysis CCF

12 Functional Safety Roadmap 1. Determine the Required Performance Level Perform Risk Assessment considering all hazards 2. Decide on the Architecture/Category Cat B, 1, 2, 3, 4 3. Collect Data From vendor documentation or libraries 4. Do the PL Calculation Manually or leverage software tools

13 13 Types of Categories (Structure) CAT B/1 CAT 2 CAT 3 CAT 4 (higher diagnostic coverage that CAT 3)

14 Functional Safety Roadmap 1. Determine the Required Performance Level Perform Risk Assessment considering all hazards 2. Decide on the Architecture/Category Cat B, 1, 2, 3, 4 3. Collect Data MTTFd From vendor documentation or libraries MTTFd Mean Time to Dangerous Failure Low 0-10 Years Medium Years High Years 4. Diagnostic Coverage and PL Verification DC Diagnostic Coverage = Detected Dangerous Failures / All Dangerous Failures None DC < 60% Low 60 < DC < 90% Medium 90 < DC < 99% High DC >99% Utilize SISTEMA Software

15 Performance Level Balancing Structure (Cat), Reliability (MTTFd) and Diagnostic Coverage (Dcavg) Performance Level PLr a b c d e Structure (Category) Designated Architecture Designated Architecture Designated Architecture Designated Architecture Designated Architecture Designated Architecture Designated Architecture Cat B Cat 1 Cat 2 Cat 2 Cat 3 Cat3 Cat 4 Diagnostic Coverage (DC) DC avg DC avg DC avg DC avg DC avg DC avg DC avg <60% <60% Reliability (MTTF) 60% to < 90% 90% to < 99% 60% to < 90% 90% to < 99% 99% 15

16 16 Introduction to SISTEMA & Safety Automation Builder Copyright 2016 Rockwell Automation, Inc. All rights reserved.

17 Leverage SISTEMA for Real Time Validation SISTEMA Safety Integrity Software Tool for the Evaluation of Machine Applications SISTEMA provides a comprehensive method for evaluating ISO compliant Safety Control Circuits The tool enables you to model the structure of the safety-related control components based upon the designated architectures. The tool offers automated calculation of a safety function s attained PL by using product data provided by safety product manufacturer. SISTEMA is a free software tool designed by Germany s IFA (Institute for Occupational Safety & Health). SISTEMA simplifies the PL calculation of a safety function Discover.RockwellAutomation.com Copyright

18 18 SISTEMA Terminology Relationship of 7 Hierarchical Levels in Sistema - Project: Refers to machine or summary of safety functions - Safety Function: Safety oriented response to an triggering event -Subsystem: Group of Blocks within a defined structure Input - Logic - Output -Channel: Connection of Blocks in series -Block: Component in the function or test channel -Test Channel: Confirms safety function channel is executing properly -Element: Component reliability measure expressed as B10d value by vendor. Number of cycles until 10% of sample fail dangerously Safe operating stop Channel 1 Channel 2 linkage INPUT LOGIC OUTPUT Switch channel 1 linkage contacts contacts Switch channel 2 Logic Device Safety Output Contactor 1 Safety Output Contactor 1 when a guard door is opened

19 Sistema Project View

20 20 SISTEMA RA Library View SISTEMA User Interface Library View Library Selection Rockwell Automation Product Library Attribute Tabs Product Data

21 21 Sistema Report View

22 Copyright 2009 Rockwell Automation, Inc. All rights reserved. SISTEMA Data created & exported Review the SISTEMA project information to ensure that the components, structure and design meet the required Performance Level

23 23 SISTEMA TUV Recommended SISTEMA is the ONLY software tool recommended by TÜV! We recommend [SISTEMA]. The important thing to us as a third party assessor is that [SISTEMA] is from a German governmental agency, so it s not attached to any particular vendor of components its neutrality is more reliable. From TÜV Webinar in March 2009: - Frank West Senior Product Safety Service Engineer, TÜV SUD

24 24 Free Software Download Safety Solutions To Access the Safety Portal

25 Safety Automation Builder No-charge Software tool to help design a Machine Safety System

26 Create a Project Name, description, etc. here

27 Choose or Import Graphics Machine Images

28 Risk Assessment Questions Answer Risk Assessment Question Answer Safety Function Question Answer Required PL Question Select the default PL for the system

29 Define Functional / Safety Zones Click the zone shape and drag it onto the image Re-size & rotate as needed

30 Define Functional / Safety Zones Click the hazard tab to create a hazard Click the type of hazard then select & drag the icon onto the image then re-size as needed

31 Select & Configure Devices Input selection box for choose a product type Click on the configure box to start Raise

32 32 Copyright Rockwell Automation, Inc. All rights reserved. Free Software Download Safety Solutions To Access the Safety Portal

33 Introducing Common Safety Functions Library

34 Introducing Common Safety Functions Library Examples for safety relay and safety PLC systems Breadth of examples including E-stop Light Curtains (Muting & Non-muting) Two hand control Enabling Switch Guard-locking switches Door interlocks Thorough documentation, wiring, programming, analysis, and more

35 35 Machine Safety Symposium